Strain gauge with moisture barrier

ABSTRACT

A device for mounting on a structure surface includes a component, a circuit, a moisture barrier, and a protective cover. The moisture barrier is within the protective cover. The component and the circuit are within the moisture barrier. The component is for bonding to the structure surface with a bond susceptible to damage from moisture. The circuit includes a radio frequency transmitter. The circuit is for providing data derived from the component to the radio frequency transmitter for external transmission.

This patent application is a divisional of U.S. patent application Ser.No. 11/091,244, filed Mar. 28, 2005, now U.S. Pat. No. 7,461,560 whichclaimed priority of U.S. provisional patent application 60/556,974,filed Mar. 26, 2004.

RELATED US PATENT APPLICATIONS AND PAPERS

This patent application is related to the following U.S. patentapplications:

Ser. No. 09/731,066 to Townsend, (“the '066 application”) “DataCollection and Storage Device,” filed Dec. 6, 2000, incorporated hereinby reference;

Ser. No. 10/379,223, to Hamel, et al., (“the '223 application”) “EnergyHarvesting for Wireless Sensor Operation and Data Transmission,” filedMar. 5, 2003, incorporated herein by reference;

Ser. No. 10/379,224, to Arms, et al., (“the '224 application”) “RoboticSystem for Powering and Interrogating Sensors,” filed Mar. 5, 2003,incorporated herein by reference; and

Ser. No. 10/769,642, to Arms, et al., (“the '642 application”) “ShaftMounted Energy Harvesting for Wireless Sensor Operation and DataTransmission,” filed Jan. 31, 2004 incorporated herein by reference.

This patent application is also related to a paper by Arms, S. W. etal., “Power Management for Energy Harvesting Wireless Sensors” (“thepower management paper”), Proceedings SPIE Smart Structures and SmartMaterials, Paper no. 5763-36, San Diego, Calif., March 2005,incorporated herein by reference.

FIELD

This patent application generally relates to strain gauges. Moreparticularly it relates to a wireless strain gauge. It also relates to astrain gauge with an improved moisture barrier and with structure totest itself.

BACKGROUND

The quality of data reported by a strain gauge mounted to a metallicsubstrate depends on the integrity of the adhesive bond between thestrain sensor and the substrate. It is generally accepted that theadhesive bond (typically an epoxy) breaks down in the presence ofmoisture. Swelling of the epoxy due to moisture absorption results inshear stresses at the epoxy/metal interface, and over time, these shearstresses can result in failure of the epoxy bond and de-lamination ofthe strain gauge.

One solution to this problem, often employed on large civil structures,is to package the strain gauge within a sandwich of two hermeticallysealed stainless steel ribbons. Laser or electron beam is used toprovide the sealing. This strain sensitive ribbon is then spot welded tothe structure under test. However, this spot welding process createslocalized changes in the steel's microstructure which may be subject tohigher than normal rates of corrosion. For many applications of weldedstructures, the creation of corrosion focus points is consideredunacceptable, as these could result in degradation in the physicalappearance, added maintenance costs, or even the initiation of materialfailure. Therefore protection against moisture is desired.

None of the systems for connecting a strain sensor to a structure havebeen satisfactory in providing a reliable bond that is resistant tomoisture degradation without affecting structural properties. Inaddition, when moisture degradation occurs there has been no way torecognize that data coming from the sensor is not acceptable. Thus, abetter system for connecting strain sensors to structures is needed, andthis solution is provided by the following.

SUMMARY

One aspect is a device for mounting on a structure surface includes acomponent, a circuit, a moisture barrier, and a protective cover. Themoisture barrier is within the protective cover. The component and thecircuit are within the moisture barrier. The component is for bonding tothe structure surface with a bond susceptible to damage from moisture.The circuit includes a radio frequency transmitter. The circuit is forproviding data derived from the component to the radio frequencytransmitter for external transmission.

Another aspect is a method of protecting a strain gauge on a structuresurface. The method includes providing a structure, wherein thestructure has a structure surface. The method also includes providing astrain gauge, a moisture barrier material, and a preformed protectivecover. The strain gauge is bonded to the structure surface with a bond,wherein the bond is susceptible to damage from moisture. The structuresurface is subject to strain from a mechanical force other than thatprovided by bonding the strain gauge to the structure surface. Thebonding of the strain gauge to the structure surface is for obtainingdata related to the strain from the mechanical force. The methodincludes placing the preformed protective cover over the strain gaugeand connecting the preformed protective cover to the structure surfaceto enclose the strain gauge within the preformed protective cover. Thepreformed protective cover has an outer surface having a convexcurvature. The convex curvature extends from the structure surface. Allof the preformed protective cover facing a shear-oriented impact loadfacilitates transfer of the shear-oriented impact load into acompression load. The method includes providing the moisture barriermaterial within the preformed protective cover, wherein the preformedprotective cover has a mechanical strength sufficient to protect themoisture barrier from mechanical damage. The method also includesobtaining the data related to the strain from the mechanical force.

Another aspect is a device, comprising a structure, a strain sensor anda UV light curable adhesive. The structure has a structure surface,wherein the UV light curable adhesive bonds the strain sensor to thestructure surface.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 a is a top view of a prior art dielectrometer for cure monitoringof composite materials with a comb like structure;

FIG. 1 b is a top view of a prior art humidity sensor with a comb likestructure;

FIG. 2 a is a top view of one embodiment of a patterned capacitancesensor integrated with a strain gauge;

FIG. 2 b is a top view of another embodiment of a patterned capacitancesensor integrated with a strain gauge in which pads are formed ofwindows or stripes of metal in the bonding pad area;

FIGS. 3 a-3 c are cross sectional views of different embodiments of thecapacitance sensor integrated with the strain gauge of FIGS. 2 a, 2 bwith air, polyimide, and epoxy dielectrics;

FIG. 4 a is a schematic/block diagram of an embodiment including asensor node and a base station in which the sensor node has both astrain gauge and a moisture sensor;

FIG. 4 b is a schematic/block diagram of an embodiment including acapacitive moisture sensor and a microprocessor with an oscillator;

FIG. 5 is a flow chart showing an embodiment of a process to attach andprotect a self-testing strain gauge node to a surface of a structure;

FIG. 6 is a cross sectional view of an embodiment of a temporarymounting fixture during use for attaching a strain gauge and moisturesensor to a steel structure;

FIG. 7 is a three dimensional view of an embodiment of a tape mountedprotective cover for protecting a strain gauge and moisture sensor inwhich the protective cover includes an integrated replaceable sealedbattery and openings for wax insertion;

FIG. 8 is a three dimensional view of an embodiment of a process forfilling a protective cover with molten wax;

FIGS. 9 a-9 c are cross sectional views similar to those of FIGS. 3 a-3c with an additional thin film of wax, grease, Waxoyl or anticorrosionformula; and

FIGS. 10 a-10 c are three dimensional views of another embodiment of atape mounted protective cover for protecting a strain gauge and moisturesensor in which the printed circuit board is mounted to the protectivecover, and the protective cover also includes an integrated replaceablesealed battery and openings for wax insertion.

DETAILED DESCRIPTION

The present inventors recognized that substantial improvement in strainsensor reliability could be achieved by providing an improved moisturebarrier and by providing a self testing scheme so that delamination orother problems could be detected and the strain sensor replaced. Theyrecognized that they could provide a for the strain sensor and fill thewith wax to substantially improve resistance to moisture penetration.They also recognized that for some dielectrics capacitance of acapacitor adjacent to the strain sensor could provide data about themagnitude of moisture penetration and the potential for degradation ofthe epoxy bonding the strain sensor to the substrate surface to which itis mounted. They also recognized that the scheme could also be used tomonitor the curing of the epoxy or of other polymers.

The structure to which the strain sensor may be attached may be abuilding, a bridge, or a vehicle, such as a car, a truck, a ship,construction equipment, or excavation machinery. The structure can alsobe the spinning shaft of a motor, pump, generator or other spinningdevice.

A hard-wired system that uses a comb-like structure patterned onpolyimide as a dielectrometer for cure monitoring of composite materialsare described in a manual, “Eumetric 100A Dielectrometer Cure MonitoringSystem User's Guide,” available from Holometrix, formerly Micromet,Newton Centre, Mass. and shown in FIG. 1 a. The dielectrometer reflectsthe degree of cross-linking of the polymer chains, which can be relatedto strength. Higher dielectric constants indicate stronger materialproperties.

The dielectric constant measured in such a device is greatly influencedby the presence of moisture because the dielectric constant of air isone, but the dielectric constant of water is 80. A patterned humiditysensor developed at Dublin City University is described in a paper,“Humidity Sensors,”and includes a comb-like structure, as shown in FIG.1 b. This sensor uses polyimide as the moisture sensing dielectricmaterial because of its excellent thermal and electrical stability. Italso uses a silicon nitride substrate.

Such a capacitance monitoring technique has not previously been used tomonitor moisture in the vicinity of a strain gauge's epoxy bond orattachment to the surface of the structure to which the strain gauge isaffixed.

The present strain sensing system has the ability to monitor and reporton the integrity of its own encapsulation by monitoring the moisturecontent of the epoxy or the moisture content adjacent to the epoxy.Self-testing of the integrity of the encapsulation is accomplished bymeasuring the capacitance of a capacitance sensor that is sensitive tothe presence of moisture in the vicinity of the strain gauge/epoxy glueline attachment to the metal or other material of the structure to whichit is affixed.

Patterned capacitance sensor 20 is integrated with and provided aroundthe periphery of strain gauge 22, as shown in top view in FIGS. 2 a, 2b. Patterned capacitance sensor 20 includes interdigitated comb metalplates 20 a, 20 b on polyimide substrate 24, such as a Kapton substrate,as shown in cross section in FIG. 3 a. As shown, patterned capacitancesensor 20 is located on three sides of small 5000 ohm strain gauge 22,such as the Micro-Measurements model N3K-06-S022H-50C/DP. Capacitancesensor 20 is preferably un-encapsulated and its polyimide substrate 24is preferably in direct contact with the same epoxy adhesive 26 used toaffix strain gauge 22 to surface 28 of structure 30.

Capacitance sensor 20 and strain sensor 22 are both fabricated bylithographically providing metal lines 20 a, 20 b, 22′ on polyimidesubstrate 24, as shown in FIG. 3 a. Sensor assembly 32, includingcapacitance sensor 20 and strain sensor 22, are preferably epoxy bondedwith epoxy 26 to surface 28 of structure 30, such as a machine, bridge,vehicle or any other structure. In one embodiment, shown in FIG. 3 a,polyimide cap 34 is provided to protect metal lines 20 a, 20 b, 22′ frommechanical damage. Capacitance of capacitance sensor 20 changes asmoisture content of air dielectric 36 between plates 20 a, 20 b ofcapacitance sensor 20 changes.

In another embodiment, polyimide dielectric 36′, or another polymer thathas a dielectric constant sensitive to the presence of moisture, isprovided between plates 20 a, 20 b of capacitance sensor 20, as shown inFIG. 3 b. Alternatively, polyimide cap 34 is omitted and mounting epoxyis itself provided on the surface of capacitance sensor 20 and betweenmetal plates 20 a, 20 b to provide epoxy dielectric 36″ between plates20 a, 20 b of capacitance sensor 20, as shown in FIG. 3 c. Shouldmoisture reach mounting epoxy 26, it will also be present in airdielectric 36, polyimide dielectric 36′, or epoxy dielectric 36″, andchange the capacitance of capacitance sensor 20.

In another approach, capacitance of the strain sensor itself is used asthe moisture sensor. While electrical contact to the surface 28 ofstructure 30 would provide a two plate capacitance with polyimidesubstrate 24 and mounting epoxy 26 serving as the dielectric in thatcase, no electrical contact to the structure surface is actually needed.With a high frequency signal applied across strain gauge 22, asdescribed herein above for separate capacitance sensor 20, changes indielectric properties in its neighborhood could be detected, includingchanges from moisture penetration adjacent strain gauge 22.

The change in capacitance of capacitance sensor 20 is detected bycapacitance signal conditioning circuit 50, A/D converter 52, andmicroprocessor 54 and transmitted externally by transmitter 56 throughantenna 58, as shown in FIG. 4 a. These components are all located oncircuit board 59 that is also bonded to surface 28 of structure 30. Basestation 62 receives transmission from antenna 58 and from other sensornodes that may be nearby. Signal conditioning circuit 50 includes, sineor square wave oscillator 70 that provides a high frequency signal tocapacitive divider 72 that includes capacitance sensor 20 and referencecapacitor 74. Reference capacitor 74 has an inorganic dielectric and isinsensitive to changes in humidity. Output of capacitance divider 72will track changes in capacitance in humidity sensitive capacitancesensor 20, and this signal is amplfied in AC amplifier 76, rectified infull wave synchronous rectifier 78, and filtered in low pass filter 80to provide a DC output proportional to the difference in capacitancebetween capacitors 20 and 74. If this number stays constant thencapacitance sensor 20 has not changed and humidity has not entered.Thus, the present invention provides self-testing of the integrity ofthe epoxy bond between sensor assembly 32 and structure surface 28 andwireless transmission of the integrity data.

An alternative embodiment to determine change in capacitance ofcapacitance sensor 20 is shown in FIG. 4 b. An AC signal generated by aprogram running on microprocessor 54 derived from the microprocessorclock is provided across outputs 82, 84 of microprocessor 54. Input 86receives a signal resulting from RC delay across resistor 88 andcapacitance sensor 20. This delay will change as moisture levelincreases between plates 20 a, 20 b of capacitance sensor 20.Microprocessor 54 detects the presence of moisture based on the delaybetween output signal 82 and input signal 86.

Uni-axial, bi-axial and triaxial strain gauges, such as those availablefrom Vishay Micromeasurements, Raleigh, N.C. can be used, such as partnumbers CEA-06-125UW-350, CEA-06-125UT-350, and CEA-06-125UA-350.Principal strain magnitudes and strain directions can be computed, asdescribed in a textbook by James W. Dally & William F. Riley,“Experimental Stress Analysis”, Third Edition, Chapter 9,Strain-Analysis Methods, pp 311-315 publisher: McGraw-Hill, Inc., NY,N.Y. (c) 1991, 1978, 1965 by Dally and Reilly. These gauges includeresistors, and the resistance changes both from changes in strain andfrom changes in moisture. The gauges do not include ability to detectmoisture and do not include ability to distinguish a change inresistance due to a change in moisture from a change in resistance dueto a change in strain. The deleterious effects of moisture and some waysto waterproof are described in the Dally & Riley book on pages 196-197.The present patent application provides a way to detect both strain andmoisture and to protect against moisture.

Microprocessor 54 can receive data from capacitance sensor 20 related toany change in dielectric constant of its dielectric 36, 36′, 36″ and canreport this change to base station 62, as shown in FIG. 4 a. Informationconcerning a degraded capacitance sensor 20 that indicates the presenceof moisture in dielectric 36, 36′, 36″ between plates 20 a, 20 btransmitted to base station 62, which will sound an alarm, store thedata in memory, and mark that particular sensor assembly 32 forreplacement. Sensor assemblies 32 that exhibit capacitance within atolerance will remain in service transmitting data from surface 28 ofstructure 30 to which they are mounted. Thus, the present inventionprovides for self-testing and maintenance of sensors to ensure that theyare reliably providing accurate data and that the bonding to structuresurfaces has not degraded from moisture penetration.

FIG. 4 a also shows an energy source, such as a battery or an energyharvesting device. These supply Vsupply to processor 54. Processor 54can control power Vcc to capacitance signal conditioning 50 and A/Dconverter 52. Processor 54 can also control power Vcc′ to strain gauge22, strain gauge signal conditioning DC AMP, and the strain gauge A/Dconverter. Power Vtx can also be provided to transmitter 56 undercontrol of processor 54. Also processor 54 can write data tonon-volatile memory 57. A more detailed circuit diagram for a singlestrain gauge bridge is provided in FIG. 16 of the '642 application.Multiple strain gauge bridges can be provided, as shown in FIG. 2 of the'066 application, which includes a multiplexer.

Strain gauges have long been bonded to metal surfaces and the processfor bonding a strain gauge to a metal surface is well known in the art.A combination of heat and pressure have been used to cure a thin glueline of two-part epoxy between the strain sensing element and themetallic substrate. Over 24 hours is needed at room temperature. Abouttwo hours is needed at an elevated temperature of about 150 C. Two-partepoxy with such extended cure time has been used for best results.However, this extended time process has not been easy to deploy in thefield, especially if many strain sensor nodes need be attached to astructure. Compromises are typically made to facilitate quick curing,such as the use of cyanoacrylates (super-glues) or one-part epoxies.However, these room temperature, fast-curing adhesives do not provide asstrong a bond as extended cure time two-part epoxy, greatly limiting theuse of such glue-bonded strain gauges for long term structural healthmonitoring applications.

An improved system for in-field connection of a strain gauge to a metalor non-metal structural surface, using optimum epoxy formulations, andwith subsequent waterproof encapsulation of the strain gauge and itssignal conditioning, data logging, and wireless communicationelectronics, is needed. The finished package must be low profile,durable, low cost, and suitable for long term deployment. With theself-testing feature described herein above providing wirelesslytransmission of information about the ingress of moisture, such apackage has potential for much wider use individually or in a network ofmany such nodes than currently available packages. The application ofwireless sensors with data logging elements, signal conditioningelectronics and bidirectional electronics has been described in the '066patent application.

In addition to providing the self testing for moisture and the wirelesstransmission of this self-test data feature, the present inventors alsoprovided an improved process to attach and protect their fullyintegrated, self-testing strain gauge sensor node to a surface of astructure, as shown in the flow chart in FIG. 5. In the first step,surface 28 of structure 30 to which sensor assembly 32 is to be mountedis properly cleaned, as shown in step 200. The surface can be a steelsurface or it can be a plastic, composite or any other material.

In one embodiment strain gauge 22 and moisture sensing capacitancesensor 20 will have already been pre-wired to circuit board 59, or theycan be integral with circuit board 59. Circuit board 59 containssupporting electronics and is fully tested for proper operation at thefactory. Circuit board 59 can be fabricated of fiberglass materials,such as FR4 or of ceramic materials, such as low temperature co-firedceramics. Circuit board 59 can also be fabricated of thin flexibleinsulative materials, such as polyimide. In this embodiment strain gauge22, moisture sensing capacitance sensor 20, and circuit board 59 can beaffixed to the structure using a UV-cured epoxy adhesive, as shown instep 201. UV light is provided to adhesive located under strain gauge22, moisture sensing capacitance sensor 20, and edges of circuit board59 accessible to UV light.

In another embodiment, circuit board 59 may be mounted to protectivecover 89, as shown in FIGS. 10 a-10 b. In this embodiment lead wiresfrom strain gauge 22 and moisture sensing capacitance sensor 20, affixedwith a UV-cured epoxy adhesive, are plugged into a receptacle extendingfrom circuit board 59. Circuit board 59 mounted in protective cover 89can be protected with wax, silicone grease, or another protectivematerial in the factory with only wires and/or a receptacle extendingfor mating with lead wires from strain gauge 22 and moisture sensingcapacitance sensor 20. In this embodiment, protective cover 89 enclosesstrain gauge 22, moisture sensing capacitance sensor 20, circuit board59, and lead wires there between.

The strain and moisture sensing elements are glued directly to thestructure's steel substrate, as shown in steps 202 to, using a processmore fully described herein below. For attachment to a steel portion ofstructure 32, magnetic mounts 90 are used to temporarily attachspecially designed mounting fixture 92, as shown in step 202 and in FIG.6. Fixture 92 includes frame 94 held in position by magnetic mounts 90.

Sensor assembly 32 is applied to surface 28 of structure 30 with epoxyas shown in step 203. Threaded plunger 96 provides compression on sensorassembly 32 including strain gauge 22 and capacitance moisture sensor20. Threaded plunger 96 is tightened as shown in step 204, to providecompression force on sensor assembly 32.

Thermoelectric heating element 98 provides heat to more rapidly cureepoxy (not shown) beneath sensor assembly 32 while it is beingcompressed. Heating element 98 is turned on to cure epoxy as shown instep 205. Temperature and pressure are monitored with temperature sensor104 and pressure sensor 102, as shown in step 206, and information maybe fed back to heating element 98 and threaded plunger 96 or to theoperator allowing control over the amount of pressure and heat appliedto the assembly. Optionally, capacitance sensor 20 can be used tomonitor the state of cure during this step, as shown in step 207 andwaiting step 208, and to provide feedback about changes in thedielectric constant of the epoxy during the curing process, as describedherein above for the embodiment of FIG. 3 c. To accomplish this atemporary power source is provided to circuit board 59 during curing.Rubber pad 100 insures a stable pressure and an even pressuredistribution during curing.

Swivel 106 allows aluminum plate 108 along with heating element 98freedom of movement to accommodate a tilted surface. Aluminum plate 108provides for uniform distribution of heat from heating element 98.

After curing is complete the mounting fixture is removed, as shown instep 209. Next protective cover 89 is installed on sensor assembly 32and its supporting electronics on printed circuit board as shown in step210. Finally remaining space in protective cover 89 is filled with wax,as shown in step 211.

An alternative method for quickly attaching a strain gauge to thesubstrate is to use an ultraviolet (UV) light curable epoxy. Theseepoxies are advantageous in that they are cured to provide a strong bondin a matter of seconds with exposure to UV light. They have advantage inthat, before exposure to the UV light, the strain gauge can bere-positioned as needed, and then a few seconds exposure fixes the gaugein place. A potential problem is that UV light cannot penetrate thepolyimide materials commonly used in strain gauge construction. However,the present inventors found that fiberglass resin backed strain gaugesused for high performance transducers become clear when UV epoxy isplaced on their backing, transmit UV, and allow UV curable epoxy to beused.

In preliminary experiments the present inventors bonded severalfiberglass resin backed strain gauges from Micro-Measurements, Inc.,Atlanta, Ga., with a UV curable epoxy from Epoxy Technology, Inc.Destructive testing of the glue line indicated that a strong bond hadbeen achieved beneath the strain sensing elements. However, testingshowed delamination and that the epoxy had not been cured beneath thelarge copper bonding tab areas. Clearly the UV light did not reach theseareas. The present inventors designed a custom strain gauge with windowsor stripes of metal in the copper bonding pad area to let sufficient UVlight through to cure the epoxy in these areas, as shown in FIG. 2 b. Inaddition to soldering, attachment of lead wires to these pads can beaccomplished with electrically conductive UV curable epoxy, availablefrom Allied Chemical Co., division of Honeywell, Plymouth, Minn.

In the next step in the packaging process protective cover 89 isprovided and mounted on surface 28 of structure 30 to enclose sensorassembly 32 and circuit board 59 with its antenna 58, as shown in step204 and in FIG. 7. Preferably, cover 89 is fabricated of a clearpolycarbonate material. Protective cover 89 can include high strengthaggressive contact adhesive tape 112, available from 3M Corp.,Minneapolis, Minn., on its bottom edges for securing to surface 28 ofstructure 30. The technician doing the mounting will remove theprotective polyethylene film (not shown) covering adhesive tape 112 andvisually align battery compartment plug 114 with its mate batteryconnection header 115 on circuit board 59. Battery compartment plug 114is wired to battery compartment 116 into which battery 118 can beinserted and sealed with O-ring seal 120 on threaded battery cover 122that encloses battery 118 in threaded hole 124. Cover 89 will then bepressed onto surface 28 of structure 30 to provide a high strength bondthere between.

To maintain a long life for battery 118, the power management paperdescribes techniques to reduce power consumption, extending the life ofbattery 118. These energy saving strategies are also useful when energyharvesting systems are deployed, such as those describes in the '223patent application to Hamel and the '642 patent application to Arms. Theenergy harvesting methods could be used to eliminate battery 118 andenergy can be stored on a capacitor, as described in these patentapplications. The present inventors found that low leakageelectrochemical batteries exhibited characteristics that were favorablefor use with energy harvesting. Battery 118 can be a rechargeablebattery and energy harvesting can be used to recharge battery.Alternatively, electromagnetic energy can be provided to rechargebattery 118 as described in the '224 application. Alternatively, acharger can be plugged into the sensor node to charge battery 118.

The '642 application also provides a scheme for performing automatic andwireless shunt calibration and for adjusting offsets and gainswirelessly.

Next, wax moisture barrier 130 is provided to protect components oncircuit board 59 and sensor assembly 32 including strain sensor 22 andcapacitance sensor 20 as shown in FIGS. 7, 8. It is well known thatmicrocrystalline wax is the most effective organic barrier materialcurrently available for protecting strain gauge circuits from moisture.Wax is reported to be superior to butyl rubber and silicone rubberbecause both of these materials absorb moisture from the environmentwhile wax rejects moisture. But there are several disadvantages of usingwax barriers, including weak mechanical properties, a tendency to becomebrittle at extremely low temperatures, and a low melting point of 170deg F or 80 degrees C.

The present inventors found that problems associated with the weakmechanical strength of wax 130 could be avoided by providing wax 130inside polycarbonate protective cover 89, 110 to control and protect wax130 from mechanical damage as shown in FIG. 8. They provided injectiongun 132 filled with liquid polycrystalline wax 130 to fill protectivecover 89, 110 and encapsulate sensor assembly 32 and electronics oncircuit board 59 inside cover 89, 110 after cover 89, 110 has beenmounted to surface 28 of structure 30. Inlet filling tube 134 isconnected to threaded wax inlet hole 136 of protective cover 89, 110using polytetraflourethylene (Teflon) tubing. Molten wax 130 is injectedinto cover 89, 110 through inlet hole 136 until cover 89, 110 isvisually full of wax 130 and wax 130 begins to be extruded out of outlethole 138 and into outlet tube 140 in cover 89, 110 as shown in FIG. 8.

The present inventors found that a variety of protective materials canbe used, including wax, grease, a foam protective agent, andanticorrosion formulas, such as ACF-50. Thin film 150 of wax, grease,Waxoyl or anticorrosion formula is shown in FIGS. 9 a-9c. Waxoyl isavailable from Waxoyl AG, Basel, Switzerland. ACF-50 is available fromLear Chemical Research Corp, Mississauga, Ontario, Canada.

The foam protective agent can be a urethane expanding foam, which can beobtained from a manufacturer, such as Fomo Products, Inc., Norton, Ohio.This urethane foam is available in many forms although a 2 componentaerosol would be easiest to use in this application due to the 2 minutecure time and its ability to be sprayed through a long tube into theenclosure opening. This material is water proof, expanding, bonds tomany surfaces, and is slightly flexible. The expansion will ensure thatall of the components including the strain gauge and electronics arethoroughly coated.

In addition, vent 170, such as a vent provided by W. L. Gore andAssociates, Inc., Newark, DE, may be provided to provide pressureequalization without allowing moisture to pass, as shown in FIGS. 10 a,10 b, 10 c.

Protective cover 160 has a rounded convex outer surface with curvatureextending from the structure surface to which it is attached, as shownin FIG. 10 a. This shape facilitates transfer of many impact loads thatmight shear the adhesive bond into compression loads. Thus a fallingobject is less likely to cause breakage of adhesive tape 112 holdingprotective cover 160 to the structure surface. Protective cover 160includes printed circuit board 59 mounted to mounting bosses 164 onbottom surface 166 with screws 168, as shown in FIG. 10 b. Protectivecover bottom surface 166 includes a planar portion that is for mountingon the structure surface. Other than at a penetration extending throughthe protective cover outer surface, such as battery compartment 116, allsidewalls of the protective cover outer surface have the rounded convexouter surface with curvature extending from the structure surface towhich it is attached.

Alternatively, as shown in FIGS. 7 and 8, other than at a penetrationextending through the sidewalls of protective cover 89, 110, such as forbattery compartment 116, threaded wax inlet hole 136, or outlet hole138, all parts of the sidewalls of protective cover 89, 110 are tilted,and the tilting sidewalls extend toward each other from surface 28 ofstructure 30.

Protective cover 160 also includes adhesive tape 112 for adhesivelyattaching protective cover 160 to a structure surface, as shown in FIG.10 c. Inlet hole 136 and outlet hole 138 are provided as describedherein above, as shown in FIG. 10 a. Inlet hole 136 and outlet hole 138may be threaded to accommodate a plug and o-ring for sealing purposesafter filling is complete. Vent 170, such as a vent provided by W. L.Gore and Associates, Inc., Newark, DE, can be provided as well.

Battery compartment 116 is also provided with its cover 122 and o-ringseal 120. Positive return 172 extends from the positive terminal ofbattery 118 to printed circuit board 59. Spring 174 for the negativeterminal of battery 118 is also provided.

While the disclosed methods and systems have been shown and described inconnection with illustrated embodiments, various changes may be madetherein without departing from the spirit and scope of the invention asdefined in the appended claims. The examples given are intended only tobe illustrative rather than exclusive.

What is claimed is:
 1. A method of protecting a strain gauge on astructure surface, comprising: a. providing a structure, wherein saidstructure has a structure surface; b. providing a strain gauge and apreformed protective cover; c. bonding said strain gauge to saidstructure surface; d. placing said preformed protective cover over saidstrain gauge and connecting said preformed protective cover to saidstructure surface to enclose said strain gauge within said preformedprotective cover, wherein other than at a penetration extending throughsaid protective cover outer surface, all sidewalls of said preformedprotective cover at least one from the group consisting of (a) have arounded convex outer surface, wherein said rounded convex outer surfaceextends from the structure surface, and (b) are tilted, wherein saidtilted sidewalls extend toward each other from the structure surface;and e. providing an energy providing device, wherein said energyproviding device includes a battery, said battery being replaceablysealed within said protective cover. measured by said temperaturesensor.
 2. A method as recited in claim 1, wherein said structureincludes at least one from the group consisting of a building, a bridge,a vehicle, construction equipment, and excavation machinery.
 3. A methodas recited in claim 1, wherein said structure includes one from thegroup consisting of a car, a truck, and a ship.
 4. A method as recitedin claim 1, wherein no wires exit said Preformed protective cover.
 5. Amethod as recited in claim 4, wherein said spinning shaft is part of atleast one from the group consisting of a motor, a pump, and a generator.6. A method as recited in claim 1, wherein said preformed protectivecover is fabricated of polycarbonate.
 7. A method as recited in claim 1,wherein no wires exit said preformed protective cover.
 8. A method asrecited in claim 1, wherein said bonding said strain gauge includesproviding a light curable adhesive, positioning said strain gauge onsaid structure with said light curable adhesive, and exposing said lightcurable adhesive to light.
 9. A method as recited in claim 8, whereinsaid light curable adhesive is UV light curable, wherein said exposingsaid light curable adhesive to light involves exposing said UV lightcurable adhesive to UV light.
 10. A method as recited in claim 1,further comprising providing a microprocessor and signal conditioning.11. A method as recited in claim 1, wherein said seal includes ano-ring.
 12. A method as recited in claim 1, wherein said energyproviding device includes an energy harvesting device.
 13. A method asrecited in claim 1, wherein said connecting said preformed protectivecover to said structure surface includes adhesively bonding saidpreformed protective cover to said structure surface.
 14. A method asrecited in claim 13, wherein said preformed protective cover includesadhesive tape, wherein said adhesively bonding said preformed protectivecover to said structure surface includes bonding with said adhesivetape.
 15. A method as recited in claim 1, wherein said structureincludes a civil structure.
 16. A method as recited in claim 1, whereinsaid structure includes a machine.
 17. A method as recited in claim 1,further comprising providing a moisture barrier material within saidpreformed protective cover.
 18. A method as recited in claim 17, whereinsaid moisture barrier material includes a wax material.
 19. A method asrecited in claim 18, wherein said wax material includes at least onefrom the group consisting of wax, grease, a foam, and Waxoyl.
 20. Amethod as recited in claim 17, wherein said providing said moisturebarrier material within said preformed protective cover includessubstantially filling said protective cover.
 21. A method as recited inclaim 17, wherein said providing said moisture barrier material withinsaid preformed protective cover includes providing a thin layer on saidstrain gauge.
 22. A method as recited in claim 17, wherein saidpreformed protective cover has a mechanical strength sufficient toprotect said moisture barrier from mechanical damage.
 23. A method asrecited in claim 17, wherein said protective cover includes a first portfor filling said protective cover with said moisture barrier and asecond port for providing an exhaust while filling, wherein saidmoisture barrier material is provided after said connecting saidpreformed protective cover to said structure surface, further comprisinginjecting said moisture barrier into said first port in said protectivecover and filling said protective cover with said moisture barrier. 24.A method as recited in claim 1, wherein said structure surface issubject to strain from a mechanical force other than that provided bybonding said strain gauge to said structure surface, wherein saidbonding said strain gauge to said structure surface is for obtainingdata related to said strain from said mechanical force, furthercomprising obtaining said data related to said strain from saidmechanical force.
 25. A method as recited in claim 24, furthercomprising providing a processor, a memory, a wireless communicationsdevice, and a power supply within said protective cover, wherein saidobtaining said data related to said strain from said mechanical forceinvolves transmitting with said wireless communications device.
 26. Amethod as recited in claim 25, further comprising logging said datarelated to said strain from said mechanical force in said memory.
 27. Amethod as recited in claim 25, further comprising providing atemperature sensor within said protective cover and obtaining datarelated to temperature measured by said temperature sensor.
 28. A methodof protecting a strain gauge on a structure surface, comprising: a.providing a structure, wherein said structure has a structure surface;b. providing a strain gauge, a wireless communications device, amoisture barrier material, and a preformed protective cover, whereinsaid wireless communications device is connected for transmitting dataderived from said strain gauge for external transmission, wherein saidpreformed protective cover includes a first port for filling saidpreformed protective cover with said moisture barrier material; c.bonding said strain gauge to said structure surface with a bond, whereinsaid bond is susceptible to damage from moisture; d. placing saidpreformed protective cover over said strain gauge and over said wirelesscommunications device and connecting said preformed protective cover tosaid structure surface to enclose said strain gauge and said wirelesscommunications device within said preformed protective cover; e. aftersaid connecting said preformed protective cover to said structuresurface providing said moisture barrier material within said preformedprotective cover by injecting said moisture barrier into said first portin said protective cover and filling said protective cover with saidmoisture barrier material.
 29. A method as recited in claim 28, whereinsaid preformed protective cover has an outer surface having a convexcurvature, said convex curvature extends from said structure.
 30. Amethod as recited in claim 28, wherein said structure surface is subjectto strain from a mechanical force other than that provided by bondingsaid strain gauge to said structure surface, wherein said bonding saidstrain gauge to said structure surface is for obtaining data related tosaid strain from said mechanical force, further comprising obtainingsaid data related to said strain from said mechanical force.
 31. Amethod as recited in claim 30, further comprising providing a processor,a memory, and a power supply within said protective cover, wherein saidobtaining said data related to said strain from said mechanical forceinvolves transmitting with said wireless communications device.
 32. Amethod as recited in claim 28, wherein said protective cover furtherincludes a second port for providing an exhaust while filling with saidmoisture barrier material.
 33. A method of protecting a strain gauge ona structure surface, comprising: a. providing a structure, wherein saidstructure has a structure surface; b. providing a strain gauge, amoisture barrier material, and a preformed protective cover, whereinsaid preformed protective cover includes a vent to provide pressureequalization without allowing moisture to pass; c. bonding said straingauge to said structure surface with a bond, wherein said bond issusceptible to damage from moisture; d. placing said preformedprotective cover over said strain gauge and connecting said preformedprotective cover to said structure surface to enclose said strain gaugewithin said preformed protective cover; and e. providing said moisturebarrier material within said preformed protective cover.
 34. A method asrecited in claim 33, wherein said preformed protective cover has anouter surface having a convex curvature, wherein said convex curvatureextends from said structure surface.
 35. A method as recited in claim33, wherein said structure surface is subject to strain from amechanical force other than that provided by bonding said strain gaugeto said structure surface, wherein said bonding said strain gauge tosaid structure surface is for obtaining data related to said strain fromsaid mechanical force, further comprising obtaining said data related tosaid strain from said mechanical force.
 36. A method of protecting astrain gauge on a structure surface, comprising: a. providing astructure, wherein said structure has a structure surface; b. providinga strain gauge, a moisture barrier material, and a preformed protectivecover; c. bonding said strain gauge to said structure surface with abond, wherein said bond is susceptible to damage from moisture, whereinsaid bonding said strain gauge includes providing said strain gauge on abacking, providing a light curable adhesive, positioning said straingauge on said backing on said structure with said light curableadhesive, and exposing said light curable adhesive to light; and d.placing said preformed protective cover over said strain gauge andconnecting said preformed protective cover to said structure surface toenclose said strain gauge within said preformed protective cover; and e.providing said moisture barrier material within said preformedprotective cover.
 37. A method as recited in claim 36, wherein saidbacking includes fiberglass.
 38. A method as recited in claim 36,further comprising providing a bonding pad on said backing for providingelectrical contact to said strain gauge, wherein said bonding padincludes at least one from the group consisting of a window and a stripefor facilitating light transmission to said light curable adhesive. 39.A method as recited in claim 36, wherein said preformed protective coverhas an outer surface having a convex curvature, with wherein said convexcurvature extends from said structure.
 40. A method as recited in claim36, wherein said backing transmits UV light, wherein said light curableadhesive is UV light curable, wherein said exposing said light curableadhesive to light involves exposing said UV light curable adhesive to UVlight.
 41. A method as recited in claim 36, wherein said structuresurface is subject to strain from a mechanical force other than thatprovided by bonding said strain gauge to said structure surface, whereinsaid bonding said strain gauge to said structure surface is forobtaining data related to said strain from said mechanical force,further comprising obtaining said data related to said strain from saidmechanical force.